Connection between members

ABSTRACT

A method for preparing a more reliable connection between two members is provided. The method involves the use of a gas-removal layer which allows for gas transport in a number of overall directions in a plane of the gas-removal layer. The gas-removal layer comprises a resin and during consolidation the gas-removal layer is deformed to form a collection substantially free from entrapped gas voids. In addition, a gas-removal layer is provided as well as a mould for casting of gas-removal layers and a method for preparing such a mould. The method and the gas-removal layer provided are particularly useful for manufacturing of wind turbine blades and spars for such blades.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation of U.S. patent application Ser. No. 10/547,748,filed Sep. 2, 2005, as a national stage application ofPCT/EP2003/005630, filed May 28, 2003, now issued as U.S. Pat. No.7,731,882 on Jun. 8, 2010, herein incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to connecting of members such as memberscomprising resin and fibres. In particular, the invention relates toremoval of gas from the interface between the members during preparationof the connection.

BACKGROUND OF THE INVENTION

It is a demand within the field of structural composites to producestill larger composite structures. The size of wind turbine blades andspars for wind turbine blades is for example constantly being increasedto an extent where preparation of one-piece members requiresunacceptable resources. Such resources may for example be largeprocessing times during laying of layers and large production facilitieswith regard to apparatus size and space requirements. It is thereforedesirable to prepare the composite structures in smaller members andconnect these members to form the final structure at a later stageand/or facility.

Members to be connected may be non-cured, partially cured such aspre-consolidate or fully cured, respectively. In general, the membersare becoming increasingly rigid with the degree of curing.

Experimental work has shown that presence of voids in the interfacebetween connected members is detrimental to the mechanical performanceof the connection. As a part of the connecting procedure it is thereforetypically attempted to remove gas from the interface. However, if atleast one of the members is not rigid, i.e. not fully cured, asignificant risk remains that gas may be entrapped between the memberswithout any chance of removing it by for example applying a vacuum.

This is for example the situation in GB 2 378 995 A, where a connectionbetween two members via a compressible composite material is disclosed.The compressible composite comprises a fibrous material and a resinousmaterial. The bulk of the compressible composite is substantially devoidof air void. In use, the compressible composite member is placed betweenthe members to be connected and then formed to resemble the shape of thegap between the members by forcing the resinous material to leave thecompressible composite. As the composite structure between the membersare substantially devoid of air voids and reinforced by fibres, it maytypically possess a high mechanical strength, but the preparation methoddoes not take into account the aforementioned substantial risk ofentrapment of gas between the individual member and the compositestructure. The weak region of the combined structure as described in GB2 378 995 A is hence the interfaces between the compressible compositematerial and each of the members.

When the connection is furthermore bearing a load, such as mostconnections between members reinforced by unidirectional fibres in thelongitudinal direction of the fibres, the sensitivity towards voids inthe interface represents a major course of lack of process reliability.

There is therefore an urgent need for a method of connecting memberswithout the risk of having voids in the interface. Furthermore, theconnection between the members should be highly reproducible andreliable and possess good mechanical strength.

SUMMARY OF THE INVENTION

It is the object of the invention to provide a more reliable connectionbetween members such as members comprising resin and fibres.

The above and other objects of the invention may be realised by a methodcomprising the steps of:

-   -   providing a first member;    -   providing a second member adjacent to said first member;    -   providing a gas-removal layer in at least a part of an interface        between said first member and said second member, said        gas-removal layer allows for gas transport in a number of        overall directions in a plane of said gas-removal layer and said        gas-removal layer comprising a resin;    -   removing gas from said interface between said first member and        said second member via said gas-removal layer;    -   deforming said gas-removal layer and    -   consolidating and/or curing said interface.

The first member and/or the second member may optionally beco-consolidating and/or co-cured together with the interface.

The first and the second member preferably comprise a first and a secondresin and a first and a second type fibres, respectively. The membersmay also comprise for example fillers and/or other elements known in theart to be addable to such composite members.

The resin comprised in the gas-removal layer will be denoted third resinto distinguish it from the first and the second resin.

The first, the second and the third resin, respectively, may be based onfor example unsaturated polyester, polyurethane, vinyl ester, epoxy,thermoplastics, similar chemical compounds or combinations of these. Ina preferred embodiment, the composition of the invention of the thirdresin is compatible to first and the second resin. In another preferredembodiment, the first and the second resin have substantially the samecomposition. The third resin may or may not have substantially the samecomposition as the first resin and/or the second resin. By havingsubstantially the same composition with respect to resin composition ismeant that at least one of the main components of the resins is thesame. In a preferred embodiment, the first, the second and the thirdresin are based on one or more epoxy compositions. Actual formulationsof relevant resins are well known in the art.

The first and the second type fibres, respectively, may be based on forexample one or more fibre types selected from the group consisting ofcarbon fibres, glass fibres, aramid fibres, synthetic fibres (e.g.acrylic, polyester, PAN, PET, PE, PP or PBO-fibres, etc.), bio fibres(e.g. hemp, jute, cellulose fibres, etc.), mineral fibres (e.g.Rockwool™, etc.), metal fibres (e.g. steel, aluminium, brass, copper,etc.), boron fibres and combinations of two or more of these. In apreferred embodiment, the first and the second type fibres are the same.In a more preferred embodiment, the fibres are mainly carbon fibres.

The fibres comprised in the members may have an oriented (e.g. uniaxial,biaxial or multiaxial) and/or a random distribution, however, it ispreferred that the fibres are mainly oriented. If one or more of themembers is a laminated composite, the orientation of the individuallayers comprising fibres may or may not be the same. In a preferredembodiment, the load-bearing fibres are mainly oriented unidirectionallyin a longitudinal direction. In a more preferable embodiment of thepresent invention, the members are connected to efficiently extend thelength of the unidirectional fibres, i.e. in the longitudinal directionof the fibres.

The fibres comprised in the members may be provided as for exampleindividual or groups of fibres, fibre tows, tow pregs, woven ornon-woven fabrics, mats, semi-pregs, prepregs, pre-forms or acombination of two or more of these.

The members to be connected may be either unconsolidated or at leastpartially consolidated. By consolidated is meant that most (preferablyall) gas has been removed from inside the member. The consolidation mayfor example involve heating and/or pressing and/or applying a vacuum.The consolidation may optionally involve partially or fully curing ofthe member. In a preferred embodiment, at least one of the members ispre-consolidated. An example of an unconsolidated structure within thescope of members relevant to the present invention is a pre-form asdisclosed in WO 2004/078443 incorporated herein by reference. An exampleof an at least partially consolidated pre-form is a pre-consolidatedpre-form as disclosed in WO 2004/078442 incorporated herein byreference. However, a person skilled in the art will know and be able toprepare many other types of members within the scope of members relevantfor connecting by the method according to the present invention.

The members to be connected may be uncured, partially cured or fullycured, respectively, however, the advantage of the present invention istypically more pronounced for uncured or partially cured members thanfor fully cured members. This is mainly due to the rigidity of a memberincreasing with the degree of curing, but the stickiness of the memberalso tends to decrease with increasing degree of curing. In other words,it is more likely to form gas voids at the interface if the resin of themember has a low degree of curing than if the resin of the member has ahigh degree of curing.

Even though the term cured typically refers to thermosetting resins, thepresent invention is not limited to thermosetting resins. A membercomprising a thermoplastic resin may be connected to one or more memberscomprising thermoplastic and/or thermosetting resins by the methodaccording to the invention without departing from the inventive idea.

The group of members relevant to the present invention is hence anyuncured, partially cured or fully cured; unconsolidated, partiallyconsolidated or fully consolidated composite member, which requiresconnection to another member.

It should be observed that it is within the scope of the invention toconnect a member as described hereinbefore to any type of structureusing the claimed method.

By gas is herein meant entrapped atmospheric air as well as gaseousproducts, by-products and starting materials related to the preparationprocess.

An essential feature of the present invention is the use of agas-removal layer comprising a third resin. The gas-removal layercomprises a geometrical structure, which allows for removal of gasduring processing of the connection, preferably at least duringinitiation of the consolidation and/or the curing of the connection. Thegas-removal layer should preferably be allowed for gas transport in anumber of overall directions at least in a plane of said gas-removallayer for example to control and/or prevent or diminish orientationeffects. In a preferred embodiment, gas is allowed to move in anyoverall direction in a plane of said gas-removal layer. In a preferredembodiment, the gas-removal layer comprises essentially a resin, i.e.third resin, with a geometrical structure, which allows the removal ofgas.

In a preferred embodiment, the gas transportation network of thegas-removal layer comprises a number of third resin volumes forming athree-dimensional landscape with many mountains separated from eachother. The gas transportation network hence being formed by the volumebetween the mountains or peaks. The third resin volumes may or may notbe interconnected. Interconnected third resin volumes may for example beconnected to a support as discussed below. Third resin volumes not beinginterconnected may for example be a collection of particles provideddirectly in the interface between the first and the second member asdiscussed below. In the following, the term independent third resinvolumes will denote a number of interconnected or not interconnectedthird resin volumes forming a three-dimensional landscape with a gastransportation network in at least two dimensions.

By gas transport in an overall direction is meant movement parallel to adirection from side to side of the gas-removal layer. Hence, the overalldirection does not refer to the direction within the gas-removal layeron a local scale where some parts may be closed off. The requirementthat the gas-removal layer should allow for gas transport in a number ofoverall directions should only refer to the situation prior to theinitiation of the consolidation and/or curing. However, the gas-removallayer should stay open for an extended period of time to ensure athorough removal of gas, for example in the beginning of theconsolidation and/or curing process.

By a plane of the gas-removal layer is meant an imaginary layersubstantially parallel to a main surface of the gas-removal layer on alocal scale. Hence, if the gas-removal layer is applied on a curvedsurface, such as a part of an outer surface of a polyhedron, said planemay also be curved.

To just appreciate the present invention it is crucial to recognise thedifference between preparing of an individual member and connection ofsuch members. Channels for transporting gas is known from the art ofpreparing members comprising fibres and a resin. In WO 02/094564A1, GB2376660A and WO 02/090089A1 examples of venting structures aredisclosed. However, all of these venting structures require interactionwith a fibrous material to realise sufficient venting effect. In amember, this is not a problem as fibrous material is typically presentanyway, and in some cases the fibrous material may contribute to thereinforcement of the member. When connecting two members, the situationis completely different. The introduction of a fibrous layer withsufficient thickness to effect the venting of the gas is oftendisadvantageous as the fibres typically are oriented in the plane of theinterface and hence do not contribute to the mechanical strength of theconnection. In many cases, the introduction of such a layer may evenweaken the connection as the distance between the load-bearing fibres ofthe members are separated with a greater distance if the fibres arepresent than if the fibres are not present. The methods for venting gasknown from the art of preparing members will hence not lead to areliable product if used for connecting members.

The method according to the present invention provides a ventingstructure without having the need for introduction of a fibrous materialinto the interface between the members. Furthermore, the methodaccording to the present invention is easy and fast to manufacture aswill be discussed below.

The gas-removal layer may comprise fibrous material. If fibrous materialis present, the main purpose of the fibrous material is typically to actas a carrier of the independent third resin volumes prior to theconsolidation and/or curing of the third resin. The fibre content ishence low compared to situations where the main purpose of the fibrousmaterial is to act as reinforcement or as means for gas transportation.Typically, the fibre content should be below about 25 weight-% andpreferably below about 10 weight-%.

In a preferred embodiment, however, fibrous material is included in thegas-removal layer to provide potential equalising between the members tobe connected. This is particularly relevant when the members areconductive or comprise conductive fibres. The main purpose for includingfibrous material may in such cases be the potential equalising or acombination of potential equalising and support of the independent thirdresin volumes.

The removal of gas from the interface between the members may forexample be realised via a vacuum applied on the interface, bymechanically forcing the gas out of the interface, by chemicallyreacting at least part of the gas or by a combination of at least two ofthese methods. If a vacuum method is applied, it is preferred to includethe step of providing a vacuum enclosure encompassing said interface andoptionally said first member and/or said second member. In a preferredembodiment, the vacuum enclosure is flexible such that the consolidationmay be enhanced by pressing on the interface and optionally said firstmember and/or said second member for example via a vacuum inside thevacuum enclosure or by an external press. Mechanical forcing out the gasmay for example be realised by an external press, for example bysubstantially the same pressure on the entire surface or by a sweepingand/or increasing pressure on the interface, which method may force thegas to one end of the interface.

The deformation of the gas-removal layer is intended to remove ordiminish the open volume of the gas-removal layer. This may for examplebe realised by temporarily overcoming the viscosity of the third resinfor example by mechanical pressure or—preferably—decreasing theviscosity of the third resin by heating. The lowering of the viscosityallows for the gas-removal layer to flow or melt together, therebyreducing the open volume of the gas-removal layer. In a preferredembodiment, the decreasing of the viscosity is controlled to ensure thatthe decreasing of the viscosity takes place in a zone moving through theinterface. This may ensure that the gas transport may proceed from thezone to an outer surface during the moving of the zone.

The deformation may also be realised at least partially by plasticallydeforming the gas-removal layer by an external force such as via avacuum in a vacuum enclosure or by a press. The deformation rate of thegas-removal layer is particularly high when a decrease of the viscosityof the third resin is combined with an external force.

In a preferred embodiment, the deforming of the gas-removal layer takesplace gradually starting away from a gas exit and ending near or at agas exit. This procedure is advantageous as it reduces the risk that gasmay become entrapped inside the gas-removal layer as the layer isdeformed and the open volume is removed. This may for example berealised by heating the interface inhomogeneously thereby providing aheated zone moving through the interface. In the heated zone, andoptionally behind it, the viscosity and/or the mechanical pressure issufficient to deform the gas-removal layer, whereas the part of theinterface in front of the heated zone is only affected to a limitedextent. The gas transportation network is hence open in front of theheated zone and the gas may be very efficiently removed from theinterface.

The thickness of the deformed gas-removal layer after completeconsolidation and/or curing is typically in the order of 100 μm to 500μm and preferably in the order of 200 μm to 300 μm, however, layershaving much greater thickness such as 1 to 2 mm may also be feasible.The thick layers may for example be useful when relatively rigid membersare connected, particularly if the members do not fit very welltogether. The thin layers are particularly feasible when at least one ofthe members to be connected is relatively soft and hence may complyclosely with the other member.

The viscosity of the third resin is important to the inventive concept.The viscosity at room temperature should be sufficiently high to ensure,that the individual third resin volumes possess sufficient mechanicalstrength to sustain gas permeability (i.e. keeping the gastransportation network open) under vacuum, preferably at least for aperiod of time in the order of minutes. This will typically correspondto the third resin being solid or semi-solid at room temperature. Duringconsolidation, the viscosity will usually be lowered. This may forexample be realised by heating. It is important, that the connection isconsolidated, i.e. the gas is removed, before the curing has finished.Preferably, the consolidation is substantially finished before the maincuring takes place. In a preferred embodiment, the gas-removal layer isheated gradually in the interface between the first and the secondmember to realise the desired deformation and consolidation in thegas-removal layer by gradually heating the interface. As the temperatureis raised, the viscosity of the third resin will usually decrease untilthe curing reaction dominates and the viscosity increases again. In apreferred embodiment using an epoxy-based third resin, the lowestviscosity is realised at about 80 to 90° C. and the minimum viscosity isin the order of 10,000 to 1,000,000 cP such as about 100,000 cP.However, both higher and lower viscosity values may be desirable in somecases.

In a preferred embodiment, the third resin wets at least some of thesurrounding material such as the first and the second member and theelements of these during the deformation of said gas-removal layer. Thisis preferable since if the third resin wets surrounding material, astronger binding to this material is obtained.

In a preferred embodiment, extra resin is provided to the interfacebetween the first member and the second member. The extra resin may in apreferred embodiment be provided with the gas-removal layer, i.e. on thesame time as the gas-removal layer is provided. In a particularlypreferred embodiment, the extra resin may be an integrated part of thegas-removal layer such as a part of the structure making up a gastransportation network. It is particularly important to provide extraresin, if the members are not completely wet by their respective resins,as wetting of the fibres are needed to realise the maximum mechanicalstrength of the final composite structure.

In another preferred embodiment, excess resin is removed from theinterface and/or nearby parts of the members during the deformation ofthe gas-removal layer. Generally speaking, the resin is not as strong asthe fibre-reinforced members and if too much resin is present near theinterface, removal of excess resin may increase the mechanicalperformance of the interface and hence of the final connection. Theexcess resin may for example be removed through the gas-removal layer ifthe resin melted as a part of the consolidation process.

In a preferred embodiment, the gas transportation network is mainlyformed by the space between independent three-dimensional volumes of thethird resin. Hence, a transportation network having a very high numberof transportation channels are provided. Due to the network it is muchless likely that gas will be trapped within the interface without aroute to escape. In a more preferred embodiment, the network is formedsubstantially by the space between independent three-dimensional volumesof said third resin, and in another preferred embodiment, the network isformed solely by the space between independent three-dimensional volumesof said third resin.

The volumes of third resin may take a vast number of shapes such ascylinders, cones, spheres, cubes, cylinders and cones having a polygonalcross section, irregular lumps, etc. A person skilled in the art will beable to derive a number of relevant shapes on the basis of the presentinvention. Lines of third resin—particularly if a network of lines isdistributed—may provide for a gas transport in a number of overalldirections. However, a gas-removal layer comprising only parallel linesof third resin is disadvantageous as it is likely that one or more ofthe channels are closed off before all gas has been removed, henceleading to entrapment of gas as no alternative gas-removal route ispresent. This type of gas-entrapment is much less likely whenindependent volumes of third resin are used, as a number of alternativegas-removal routes will be present until a late stage of theconsolidation and/or curing process.

The individual volumes of third resin may be distributed randomly or ina systematic method. Examples of systematic methods are trigonal,hexagonal and tetragonal geometries, straight, curved, open or closedlines and any combination of these. The size, height and distributionincluding distance between the individual volumes of third resin mayvary in broad ranges mainly depending on conditions like for example therigidity of the members to be connected (e.g. the less rigid themembers, the taller the volumes of third resin and/or the shorter thedistance between the individual volumes of third resin) and theviscosity of the third resin (e.g. the lower the viscosity of thirdresin, the taller the volumes of third resin and/or the shorter thedistance between the individual volumes of third resin). If vacuum isapplied then the volumes should have sufficiently structural strength tobe able to keep the transportation network open at least at roomtemperature. The height of the volumes and the distance between theindividual volumes should ensure that the transportation network is openat the initiation of the consolidation and/or curing reaction to ensureremoval of gas. It may be possible to derive empirical formulas forestablishing the optimum conditions in a given situation, however, suchconditions may also be derived by systematic and/or trial-and-errorexperimental work, which may be performed by a person skilled in theart.

The gas-removal layer may be provided in a number of ways dependent onfor example the degree of automation and the size of the members. In afirst embodiment, the gas-removal layer is provided by a methodcomprising the following steps:

-   -   providing an at least semi-solid third resin, optionally by        cooling;    -   dividing said third resin to obtain an at least semi-solid third        resin granulate;    -   distributing said at least semi-solid third resin granulate to        form a gas-removal layer having a gas transportation network,        which provides for gas transportation in a number of overall        direction in a plane of said gas-removal layer.

By at least semi-solid is meant semi-solid or solid. By semi-solid ismeant a highly viscous fluid or a soft solid.

By granulate is meant discrete particles of third resin of any regularor irregular shape and size. Granulate shapes may for example bespherical, polygonal, cylindrical, plate-like, cigar-like, chip-like,semi-spherical or a combination of any of these. However, the shapes arenot limited to these examples and a person skilled in the art will beable to give more examples of possible shapes. The individual granulateparticles may have similar shape and size, however, this is not arequirement. In a preferred embodiment, a range of shapes and/or sizesof granulate particles are utilised in the preparation of oneconnection.

By this embodiment, a very simple method of obtaining a gas-removallayer having a gas transportation network is provided. The dividing ofthe third resin may involve any known technique for dividing a solid orsemi-solid third resin, such as for example cutting, grinding, gratingor rubbing. Alternatively, the granulate may be formed as an integratedpart of the formulation of the third resin such as e.g. forming ofgranulate particles from a liquid prior to solidification.

If the third resin is sticky at room temperature it may advantageouslybe stored at reduced temperature. When the third resin heats to roomtemperature, the sticky nature of such a third resin may then help tofix the connection in position until the curing of the interface.

The dividing and the distributing of the third resin may easily beautomated for example by robotics and this embodiment may hence be easyand fast to manufacture.

In a second embodiment, the gas-removal layer is provided by a methodcomprising the following steps:

-   -   providing a liquid third resin, optionally by heating;    -   distributing said liquid third resin to form a gas-removal layer        having a gas transportation network, which provides for gas        transportation in a number of overall directions in a plane of        said gas-removal layer;    -   optionally cooling and/or reacting said third resin to an at        least semi-solid state.

By applying the third resin in a liquid state, it is easier to controlthe size and/or the distribution of the third resin to realise thedesired gas-removal layer. The third resin may for example be applied asdots, areas, lines, etc. The distribution may be random or organised.

If the third resin is liquid at room temperature and the chosen methodinvolves providing a vacuum on the interface, it is preferred to applythe vacuum on the interface while the third resin is in an at leastsemi-solid state to prevent premature deformation of the gastransportation network.

In a preferred embodiment of the above methods for providing agas-removal layer, the third resin is distributed directly in theinterface between said first member and said second member. In a morepreferred embodiment, the third resin is distributed directly on atleast one of said first and second members before connecting said firstand second member. This method is particularly suited for a fullyautomated process, for example by robotics.

In another preferred embodiment of the above methods for providing agas-removal layer, the third resin is provided on a support, which islater introduced into the interface. This may be advantageous, if thegas-removal layer is prepared in advance to or at another location thanthe connection of the members. The parts for the connection may then beprepared at a central facility, whereas the actual formation of theconnection may take place at the site of the final application of thecomposite structure.

This may for example be realised by the following steps:

-   -   providing a support in connection with said third resin to        enhance handling of said gas-removal layer    -   optionally heat said gas-removal layer to provide for a stronger        binding between said support and said third resin;

said support is a sheet-like member mainly comprising a resin and/or afibrous material, like for example a woven or non-woven fabric, aprepreg, a semi-preg, a web or sheet of resin and/or fibres, a veil, arelease paper, etc.

The optional heating to provide a stronger binding is particularlyrelevant if the third resin is unsticky at room temperature. In manycases, the sticky nature of the third resin will be sufficient to holdthe cover sheet connected to the gas-removal layer. It is preferred butnot required that the support is flexible as this may facilitate theadjustment of the shape of the gas-removal layer to the shape of theinterface.

In a preferred embodiment, the support consists of a resin, which may ormay not have the same composition as the third or any other of theresins. This embodiment is advantageous in that it does not introducefibrous material into the interface during establishing of theconnection. The support resin is preferably shaped as a sheet or as aweb. By web is meant lines of resin forming an at least two-dimensionalnetwork.

By veil is for example meant a non-woven, open, gas permeable web ofrandomly distributed carbon fibres held together by an organic binder.An example of a relevant veil is a carbon veil.

The support material may or may not be separated from the gas-removallayer when the gas-removal layer is applied.

In a third embodiment for providing a gas-removal layer, the gas-removallayer is provided by a casting technique preferably comprising thefollowing steps:

-   -   providing a mould, said mould does not stick significantly to        the third resin;    -   casting a gas-removal layer having a gas transportation network,        which provides for gas transportation in a number of overall        directions in a plane of said gas-removal layer, and    -   optionally providing a support to enhance handling of said        gas-removal layer, said support is a sheet-like member mainly        comprising a resin and/or a fibrous material, like for example a        woven or non-woven fabric, a prepreg, a semi-preg, a web or        sheet of resin and/or fibres, a veil, a release paper, etc.

Examples of relevant moulds are silicone or coated metal moulds. An easyway to prepare a mould is to prepare a positive image of the desiredgas-removal layer and subsequent make a cast using a silicone material.When the silicone is cured, the silicone may be used as a mould. Otherways to prepare moulds and other types of moulds are known in the artand gas-removal layers prepared by such moulds are hence within thescope of the invention.

The production of cast gas-removal layers may advantageously beautomated as well as preparing of a connection using a cast gas-removallayer for connecting two members.

In a preferred embodiment, the mould provides for formation of a networkbetween the parts making up the gas transportation network. This may forexample be formed as a web or as a continuous or non-continuous sheet,however, the web or the non-continuous sheet is preferred.

Alternatively, a support equivalent to that described above may beapplied prior to or after the casting. In a preferred embodiment, anopen web of fibres is applied to the mould prior to the casting andhence a very strong connection between the fibres and the cast thirdresin may be realised. The open web may for example be a veil, a wovenor non-woven fabric, a prepreg, a semi-preg, fibre tows or tow-pregs.

Any of the above embodiments for providing a gas-removal layer mayfurther comprise the step of providing a cover sheet on the gas-removallayer to form a sandwich gas-removal layer for enhanced handling. Thecover sheet may for example by a sheet-like member mainly comprising aresin and/or a fibrous material, like for example a woven or non-wovenfabric, a prepreg, a semi-preg, a web or sheet of resin and/or fibres, aveil or a release paper.

The cover sheet may or may not be of the same type as the optionalsupport. Such a sandwich gas-removal layer is well suited for shippingand/or storing, as the risk of stacked sandwich gas-removal layerssticking together is reduced compared to the gas-removal layers withoutthe cover sheet. Furthermore, some of the chemical substances in resinsare hazardous and a cover sheet may reduce the amount of direct contact.

In a preferred embodiment of the invention, the gas-removal layer isprovided as an integrated part of at least one of said first and secondmembers. The gas-removal layer may for example advantageously beprovided on the member as a part of the preparation of the member. Thismay save time and equipment for the connection procedure.

In another aspect, the invention provides a gas-removal layer, whichcomprises a support supporting a third resin, the third resin has a gastransportation network and said gas transportation network provides forgas transportation in a number of overall directions in a plane of saidgas-removal layer. Such a gas-removal layer is particularly suited forremoval of gas from the interface between two members to be connected asdiscussed hereinbefore. In a preferred embodiment, the gas-removal layeris flexible to ensure that it may conform to the members to beconnected.

In a preferred embodiment, the gas transportation network is mainlyformed by the space between independent three-dimensional volumes of thethird resin as this is a very simple and yet highly functional design asdiscussed hereinbefore.

The support member is preferably a sheet-like member mainly comprising aresin and/or a fibrous material, like for example a woven or non-wovenfabric, a prepreg, a semi-preg, a web or sheet of resin and/or fibres, aveil or a release paper. In a preferred embodiment, the support memberconsists of resin and the support member may hence be applied to aconnection without introducing fibrous material.

In a preferred embodiment of the gas-removal layer, the gas-removallayer further comprises a cover sheet. The cover sheet may or may not beof the same type as the support member. A cover sheet enhances thehandleability of the gas-removal layer and particularly the storage andshipping properties are enhanced, as the layers with cover sheets areless prone to stick together even if they have been placed directly ontop of each other.

In another aspect of the present invention, a small amount of dry orpartially impregnated fibres or fibre-tows are integrated into agas-removal layer as described hereinbefore to form a combinedgas-removal layer. The fibres may hence provide for a limited gastransportation, however, the gas transportation via the gastransportation network formed by independent third resin volumes shouldbe dominant and the fibre content should be below about 25 weight-% andpreferably below about 10 weight-%. In a preferred embodiment, thefibres are mainly oriented in the preferred gas-removal direction ordirections. Examples of relevant fibres are the fibres mentionedhereinbefore in relation to first type fibres and second type fibres,however, it is preferred to use glass fibre and/or carbon fibres.

If one or both of the members to be connected comprises conductivematerial such as carbon fibres, there is a risk that flashover betweenthe members may take place, unless the potential on the two sides of theinterface is equalised. It is therefore highly desirable to provide anelectrical conductive connection, which will ensure potential equalisingacross the interface. In a preferred embodiment, a potential equaliseris integrated with the gas-removal layer. The electrical connection mayfor example be realised via electrically conductive fibres, such ascarbon fibres, or a metal, however, it is preferred that the potentialequaliser comprises carbon fibres.

The electrical connection between the members will typically go aroundthe gas-removal layer or through the gas-removal layer. An example of anelectrical connection going around the gas-removal layer is a tow ortow-preg comprising carbon fibres wound around the gas-removal layer,e.g. in a helix pattern or equivalent, prior to providing thegas-removal layer in the interface. An electrical connection goingthrough the gas-removal layer may for example comprise carbon fibresand/or metal pieces stitched or in another way applied through thegas-removal layer. Experimental results have shown that an electricalconnection through the gas-removal layer may also be realised by using acarbon veil as support and/or cover sheet. An electrical connection iseasiest provided in relation to the gas-removal layer when thegas-removal layer comprises a support and/or a cover sheet. It should beobserved that the electrical connection does not need to be establisheduntil during the curing of the structure. In case of the gas-removallayer, it should hence be considered that the gas-removal layer ishighly deformed during the consolidation and/or curing of the interface,where the distance between the members is reduced and the connection mayoften relatively easy be established during this.

The gas-removal layers according to the present invention isparticularly useful for removal of gas from an interface between a firstmember and a second member during preparation of a connection betweenthe members, as it has been described previously. Particularly, thegas-removal layer is useful when at least one of the members isnon-rigid.

The gas-removal layer and the method according to the present inventionare particularly useful for preparing of a wind turbine blade andparticularly a spar for a wind turbine blade and a shell for a windturbine blade as these composite structures are very long parts, whichmay advantageously be prepared in smaller sections that are latercombined. Furthermore, these composite structures are load-bearing, andgood mechanical quality and reproducibility, which are some of theadvantages of the present invention, are detrimental to the performanceof the final structures.

BRIEF DESCRIPTION OF THE FIGURES

The invention will be explained in more detail below with reference toparticularly preferred embodiments as well as the drawings, in which

FIG. 1 shows two members and a gas-removal layer,

FIG. 2 shows a gas-removal layer,

FIG. 3 shows a member with an integrated gas-removal layer,

FIGS. 4A-4D show a mould and a cast gas-removal layer, in which FIG. 4Ashows the mould, FIG. 4B shows the cast gas-removal layer, FIG. 4C is across-sectional view of the mould taken along line C-C in FIG. 4A, andFIG. 4D is a cross-sectional view of the cast gas-removal layer takenalong line D-D in FIG. 4B; and

FIGS. 5A-5D show a mould for casting of a gas-removal layer with asupport web, in which FIG. 5A is a top view of the mould, FIG. 5B is across-sectional view of the mould taken along line B-B in FIG. 5A, FIG.5C is a cross-sectional view of the mould taken along line C-C in FIG.5A, and FIG. 5D is a cross-sectional view of the mould taken along lineD-D in FIG. 5A.

All the figures are highly schematic and not necessarily to scale, andthey show only parts which are necessary in order to elucidate theinvention, other parts being omitted or merely suggested.

In FIG. 1, the first member 2 and the second member 4 to be connectedare shown. The interface angle a is the angle between the face, whichwill be the interface 8 between the first and the second member whenconnected, and a side of the first member 2. In FIG. 1, a is drawn withan angle considerably smaller than 90°. If a is decreased, the area ofthe interface 8 is increased, which will usually lead to a strongerconnection if the interface is free from gas voids. In a preferredembodiment, a is less than about 10° but an even better connection mayby obtained when the angle is less than about 2°. If the memberscomprise fibres, which are very stiff such as carbon fibres, a may insome cases advantageously be as low as 0.5° to 1° or even lower. This isparticularly advantageous when the members are reinforced byunidirectional fibres via the connection. The low a angles may thenallow for side-by-side connection between the fibres of the first andthe second members, which are preferable compared to end-to-endconnection realised with larger a angles.

A gas-removal layer 6 is shown between the members 2,4. The gas-removallayer has a number of independent third resin volumes 12 forming a gastransportation network and a support 10. The main task of the support 10is to fix the relative positioning of the independent third resinvolumes. The number of third resin volumes 12 has been reduced forreasons of clarity. Typical values with regard to size of theindependent third resin volumes are height of about 1 to 3 mm with adiameter of about 4 to 6 mm and separated by about 10 mm between thecentres, which correspond to about between 4 to 6 mm between respectiveedges of the volumes of resin. In one advantageous form, the respectivediameters of the volume of resins in the plane of the gas-removal layerare smaller than distances between respective volumes of resin. However,the size and separation may vary considerably dependent on viscosity ofthe third resin and the properties of the members (e.g. rigidity). Theheight may for example vary between about 0.1 mm to 5 cm or even more,the separation may for example vary between about 1 mm to 20 cm or evenmore and the diameter may for example vary between about 1 mm to 5 cm oreven more. The geometrical shape of the independent third resin volumesmay in principle be any shape as long as it allows for formation of agas transportation network, however, simple geometrical shapes such asspheres, semi-spheres, cylinders, cones, cubes or truncated geometricalshapes are preferred. The size and separation of the individualindependent third resin volumes may be the same for all the third resinvolumes or it may vary. For example the height of the third resinvolumes are larger near the gas exit in a preferred embodiment.

In FIG. 1, it is indicated that the connection will lead to a linearextension of the first member. Other types of feasible connections arefor example T-connections (i.e. where a member is connectedsubstantially orthogonally to another member), L-connections (i.e. wherea member is connected substantially orthogonally to another member nearor at the end), Y-connections (i.e. where two or more members areconnected at an angle different from 90°), face-to-face (i.e. where twomain surfaces of the members are connected). A person skilled in the artwill based on these examples be able to derive other feasibleapplications of the method according to the invention.

In FIG. 2, a gas-removal layer 6 with a cover sheet 14 is shown. Thecover sheet may for example be a release paper or comprise a fibrousand/or a resinous material. Typically, the main task of the cover sheetis to enhance handling of the gas-removal layer. However, the coversheet may serve other purposes such as for example allow for stacking ofgas-removal layers during transportation and/or storage or protectingthe independent third resin volumes from damage (e.g. mechanical,chemical, thermal, etc.). The cover sheet may or may not be removedprior to the formation of the connection.

In a preferred embodiment particularly suitable for connectingelectrically conductive members or members comprising electricallyconductive fibres, the support 10 and the cover sheet 14 comprise anopen web of conductive fibrous material. The web may for example be acarbon veil or another material possessing equivalent relevantproperties.

In FIG. 3, a first member 2 with an integrated gas-removal layer 6 isshown. In a preferred embodiment, the independent third resin volumes 12of the gas-removal layer 6 are distributed on an interfacing part of themember as one of the final steps of the member preparation. This maysave considerable amounts of time and equipment in preparing theconnection as equipment being able to distribute the independent thirdresin volumes 12 is often used during the manufacturing of the members.The member 2 with integrated gas-removal layer 6 as shown in FIG. 3 maybe connected to a member with or without an integrated gas-removallayer. In a preferred embodiment (not shown), the a cover sheet and/or asupport is further provided with the integrated gas-removal layer forexample to enhance handling and/or potential equalising between themembers to be connected.

In FIG. 4, an example of a mould 20 for casting of gas-removal layersare shown. In FIG. 4A, the mould 20 is observed from a topsideperspective. A number of depressions 22 are visible in the inner mouldsurface 26. The mould may be rigid or flexible and preferably the innermould surface 26 should not stick to the third resin of the gas-removallayer. In FIG. 4B, the cast gas-removal layer 6 is observed. Thegas-removal layer may for example be prepared by distributing a thirdresin such as an epoxy resin into the depressions 22 in the mould 20shown in FIG. 4A by gravity or with the use of a suitable tool such as aspatula or a filling knife. In a preferred embodiment, the third resinwill substantially only be present in the depressions. Then the supportis placed on the mould in contact to the third resin and aftersolidification of the third resin (e.g. by cooling) the gas-removallayer may be removed. If a flexible mould is used, the mould may be bentto enhance release of the gas-removal layer. The depressions 22 in FIG.4A are hence forming the independent third resin volumes 12. Theindependent third resin volumes 12 are held together by a support layer10, which for instance may be a carbon veil or another suitable materialas discussed elsewhere. In FIG. 4C, a cross section through somedepressions 22 of the mould 20 is shown. The depressions 22 of the mould20 shown in FIG. 4A are distributed in rows, however, most other typesof distributions are feasible including regular patterns like hexagonal,trigonal, tetragonal and irregular patterns. It is, however, requiredthat the relationship between the shape, size and distribution of theindependent third resin volumes provides for the formation of a gastransportation network that is open at least on the initiation of thegas-removal process. In FIG. 4D, a cross section of the gas-removallayer 6 is shown. It is observed that the independent third resinvolumes 12 are held together by the support 10. Further, distancesbetween the respective bases of the third resin volumes 12 with thesupport 10 are greater than respective diameters of the bases of thevolumes of resin 12. Consequently, the volumes of resin 12 have at leastone dimension in the plane of the gas-removal layer which is smallerthan the distances between respective volumes of resin 12.

In FIG. 5, a mould 20 with a third resin indicated by hatched areas isshown. The mould is suitable for preparing a gas-removal layer having asupport web 30 for connecting the independent third resin volumes 12. InFIG. 5A, a top view of the mould 20 is shown. The independent thirdresin volumes 12 are cylindrical depressions 22 (but any other castablegeometry or combination of geometries is feasible such as e.g. invertedcones, semi-spheres, cubes, etc.) into the inner mould surface 26. Thesupport web 30 for holding the independent third resin volumes 12together is prepared in channels between the third resin volumes 12 butother castable geometries are feasible. It should be noted that thesupport web 30 is within the scope of the support element mentionedhereinbefore. In FIG. 5B, a cross section along the line B-B in FIG. 5Ais shown. The support web 30 for connecting the independent third resinvolumes is observed as relatively narrow depressions into the innermould surface 26. In FIG. 5C, a cross section along the line C-C in FIG.5A is shown. The independent third resin volumes 12 are observed withoutany connection between them in this cross section. In FIG. 5D, a crosssection along the line D-D in FIG. 5A is shown. Here, both theindependent third resin volumes 12 and the web 30 for connecting theindependent third resin volumes are observed.

In a preferred embodiment, a mould for casting of a gas-removal layer,such moulds as those shown in FIG. 4 and FIG. 5, comprises:

-   -   an inner mould surface, and    -   a number of depressions in the mould surface resembling the        desired independent third resin volumes to be cast.

The mould may be rigid with an easy release surface and/or coating orflexible with non-sticking surface, however, it is preferred that themould is flexible and more preferably the mould is made from asilicone-based material or a material having similar properties.

The mould may further comprise a number of channels connecting at leasttwo of the depressions.

Such a flexible mould for casting of a gas-removal layer may for examplebe prepared by a method comprising the steps of:

-   -   preparing a positive, three-dimensional surface of the desired        structure;    -   providing a silicone-based resin or a material having similar        properties on the three-dimensional surface,    -   curing the silicone-based resin, and    -   removing the silicone-based resin after curing of the        silicone-based resin, whereby the flexible mould is provided.

This method and the mould are easy to use and provide moulds of suitabledesign flexibility and strength for the production of gas-removal layersby casting.

TABLE FOR IDENTIFICATION

-   2 First member-   4 Second member-   6 Gas-removal layer-   8 Interface between first member and second member-   10 Support-   α Interface angle-   12 Independent third resin volume-   14 Cover sheet-   20 Mould-   22 Depression-   26 Inner mould surface-   30 Support web

Although the invention has been described above in relation to preferredembodiments thereof, it will be understood by those skilled in the artthat variations and modifications can be effected in these preferredembodiments without departing from the scope and spirit of theinvention.

The invention claimed is:
 1. A method for functionally connecting afirst member, comprising first fibres and a first resin, and a secondmember, comprising second fibres and a second resin, said methodcomprising the steps of: providing said first member; providing saidsecond member adjacent to said first member; providing a gas-removallayer in at least a part of an interface between said first member andsaid second member, said gas-removal layer allowing for gas transport inall overall directions in a plane of said gas-removal layer, saidgas-removal layer comprising a third resin, and a gas transportationnetwork is mainly formed by the space between independentthree-dimensional volumes of said third resin wherein the gas-removallayer comprises discrete volumes of the third resin, the volumes of thethird resin having at least one dimension in the plane of the gasremoval layer which is smaller than distances between respective volumesof resin; removing gas from said interface between said first member andsaid second member via said gas-removal layer; deforming saidgas-removal layer; consolidating and/or curing said interface; andoptionally co-consolidating and/or co-curing said first member and/orsaid second member.
 2. The method according to claim 1, furthercomprising the step of providing a vacuum enclosure encompassing saidinterface and optionally said first member and/or said second member. 3.The method according to claim 1, wherein the deforming of saidgas-removal layer involves temporarily decreasing the viscosity of saidthird resin.
 4. The method according to claim 1, wherein during thedeforming of the gas-removal layer, said third resin wets at least someof the surrounding material.
 5. The method according to claim 1, whereinthe deforming of said gas-removal layer involves an external force. 6.The method according to claim 1, wherein the deforming of saidgas-removal layer takes place gradually starting away from a gas exitand ending near or at the gas exit to reduce the risk of gas entrapmentby heating the interface inhomogeneously, thereby providing a heatedzone moving through the interface.
 7. The method according to claim 1,wherein the height and spacing of said independent three-dimensionalvolumes are adjusted to ensure that said gas transportation network isopen until a suitable amount of gas has been removed.
 8. The methodaccording to claim 1, further comprising the following steps forproviding said gas-removal layer: providing an at least semi-solid thirdresin, optionally by cooling; dividing said third resin to obtain an atleast semi-solid third resin granulate; and distributing said at leastsemi-solid third resin granulate to form a gas-removal layer having agas transportation network, which provides for gas transportation in anumber of overall directions in a plane of said gas-removal layer. 9.The method according to claim 8, wherein the third resin is distributeddirectly in said interface between said first member and said secondmember.
 10. The method according to claim 8, further comprising the stepof: providing a support in connection with said third resin to enhancehandling of said gas-removal layer, and optionally heat said gas-removallayer to provide for a stronger binding between said support and saidthird resin, such that said support is a sheet-like member mainlycomprising a resin and/or a fibrous material.
 11. The method of claim10, wherein the fibrous material is selected from the group consistingof a woven or non-woven fabric, a prepeg, a semi-preg, a web or sheet ofresin and/or fibres, a veil and a release paper.
 12. The methodaccording to claim 8, further comprising the step of providing a coversheet on the gas-removal layer to form a sandwich gas-removal layer forenhanced handling, said cover sheet is a sheet-like member mainlycomprising a resin and/or a fibrous material.
 13. The method of claim12, wherein the fibrous material is selected from the group consistingof a woven or non-woven fabric, a prepeg, a semi-preg, a web or sheet ofresin and/or fibres, a veil and a release paper.
 14. The methodaccording to claim 1, further comprising the following steps forproviding said gas-removal layer: providing a liquid third resin,optionally by heating; distributing said liquid third resin to form agas-removal layer having a gas transportation network, which providesfor gas transportation in a number of overall directions in a plane ofsaid gas-removal layer; and optionally cooling and/or reacting saidthird resin to an at least semi-solid state.
 15. The method according toclaim 1, wherein the gas-removal layer is provided by the followingsteps: providing a mould; casting a gas-removal layer having a gastransportation network, which provides for gas transportation in anumber of overall directions in a plane of said gas-removal layer; andoptionally providing a support to enhance handling of said gas-removallayer, said support is a sheet-like member mainly comprising a resinand/or a fibrous material.
 16. The method of claim 15, wherein thefibrous material is selected from the group consisting of a woven ornon-woven fabric, a prepeg, a semi-preg, a web or sheet of resin and/orfibres, a veil and a release paper.
 17. The method according to claim 1further comprising the step of providing extra resin to said interfacebetween said first member and said second member.
 18. The method ofclaim 17, wherein at least some of said extra resin is provided withsaid gas-removal layer.
 19. The method of claim 17, wherein at leastsome of said extra resin is provided as an integrated part of saidgas-removal layer.
 20. The method according to claim 1, wherein thegas-removal layer is provided as an integrated part of at least one ofsaid first and second members.
 21. The method according to claim 1,further comprising the step of providing a potential equalizer betweensaid first member and said second member.
 22. A method according toclaim 21, wherein an electrical conductive connection is establishedduring the curing.
 23. The method of claim 21, wherein the potentialequalizer is integrated with the gas-removal layer.
 24. The method ofclaim 1, wherein said third resin has a gas transportation networkmainly being formed by the space between independent three-dimensionalvolumes of said third resin, said gas transportation network providesfor gas transportation in all overall directions in a plane of saidgas-removal layer, and wherein said gas-removal layer further comprisesa support upon which the third resin is disposed, said support being asheet-like member mainly comprising a fibrous material.
 25. The methodof claim 1, wherein the gas-removal layer further comprises a coversheet to enhance handling.
 26. The method of claim 1, wherein the firstmember, second member and interface form part of a wind turbine blade.27. The method of claim 26, wherein the gas-removal layer is used in aspar for a wind turbine blade.
 28. The method of claim 27, wherein thegas-removal layer is used in a spar or blade of a wind turbine blade.29. The method according to claim 1 further comprising using the methodto prepare a wind turbine blade.
 30. The method of claim 1 wherein thevolumes of resin have dimensions of height, width and length less thanthe distances between the volumes of the third resin.